Technical Instruction Manualalkus plastic sheets

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Panel facing without swelling or shrinkageHow often is it happening that plywood is already penetrated by moisture after only a few applications? This leads to changes in dimensions and the bearing capacity can sometimes drop by more than 50 %.With the alkus-sheet there is no swelling and shrinkage - once and for all. As no water can penetrate the panel, there are no changes due to moisture. Neither to the geometry nor to the mechanical values. Of course, there is also no decay due to rotting.

Nail-holding as plywoodThe alkus-sheet is nailable as plywood; however, there is no chipping off of the face veneer and no risk of being destroyed by mold. Of course, the nail pull-out strength has been confi rmed by comparative tests with plywood.

Simple repairThe alkus-sheet is repaired with the same plastic material as the upper layer consists of. This increases the quality of the repair and extends the life span of the panels.

Favorable eco-balanceThe plastic surface of the alkus sheet does not enter into a chemical reaction with concrete and the cleaning effort is reduced to a minimum.Last but not least: old and used up alkus-sheets can be recycled into identical products, without consumption of timber resources.

Use of self-compacting concreteThe technology institute "Heidelberger Technologie Center HTC" highly recommends the use of solvent-based release agent when using special or self-compacting concrete.

June 2010

If the special concrete has a retarded setting by using fl y ash, the stripping time is extended. If this extension is not observed and the form work is stripped too early, the top concrete layer might adhere to the facing, because the concrete strength at the surface is still too less.

Extremely long life spanThe sum total of advantages:

• no destruction due to moisture• no chipping off of face veneer during nailing• no decay due to mold• repair with the same plastic material as the upper layer results in a life span of the alkus-sheet as long as the life span of the frame.

Acceptance for returnMEVA guarantees the acceptance of returnedalkus-sheets, worldwide.

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Contents

Development of the fl exural modulus of elasticity during the different project stages form July 1992 to the current panel structure.

The alkus-sheet consists of a fi ve-layer sandwich construction:Layer 1: plastic layerLayer 2: aluminum or fi bersLayer 3: foamed plastic core

Please note:

The technical manual contains information, instructions and hints how to use the alkus-sheets and the related tools. When using our products, the federal, state and local codes and regulations must be observed.What is shown on the following pages are assembly sketches for demonstration purposes. To display details more clearly, safety factor aspects are not always included.Most examples shown are standard applications as they occur in practice most frequently. In case of problems or special cases not dealt with in this manual, please contact the MEVA experts for advice.

Features ...................................................................................4Treatment ................................................................................ 5Repair....................................................................................... 6Cleaning and replacement ..................................................... 7Recycling .................................................................................. 8Technical data.......................................................................... 9

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Features

Improved concrete surfaceUntil now, the swelling of the plywood facing required the frame profi le to project past the plywood face. This resulted in the profi le nose leaving a mark in the concrete. With the alkus- sheet this is no longer a concern as thickness growth due to moisture is a thing of the past (Fig. 4.1 - Fig. 4.3).

Hints on nailingWe recommend hammering the plastic mass projecting around the nail holes after the nails have been pulled out with a hammer (Fig. 4.4).This fl attens the surface again, and no water or slurry can leak through the holes while pouring.Penetrating water (e.g. rain or cleaning from the other side) is no problem for the alkus-sheets and does not harm or damage them.

The crucial feature of the alkus-sheetis the fact that no moisture can penetrate the sheet, and therefore there is no swelling and no shrinkage.Surface damage (nailing, screwing, sawing, etc.) does not result in destruction or decay caused by water, and consequently there is no decrease in bearing capacity during the whole life span.

Increased fl exural stiffness by thicker sheetsAs the profi le noses of the formwork panels need to have a projection to compensate for the swelling of the plywood, the alkus-sheets can be built in approx. 5/64" (2 mm) thicker, since they do not in- crease in thick ness. This means, that the fl exural stiffness E x I (modulus of elasticity x moment of inertia) improves by 37 % for a 0.79" (20 mm) alkus-sheet compared to 0.71"(18 mm) plywood.

Fig. 4.1 Fig. 4.2

Fig. 4.3Fig. 4.4

Fig. 4.5

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Treatment

Effects of water-soluble release agentEspecially water-based release agent emulsions have a tendency to drip off and not to form a fi lm coating. If water-soluble release agent is applied the fi lm coating at the upper edge of the formwork might be washed away if concrete is poured by using a bucket. As there is no fi lm coating left, concrete will adhere to the formwork.

How to use solvent- based release agentAs the alkus-sheets absorb neither water nor lubricant, there is no need to oil the sheets after stripping. As experience shows, a treatment before every applica tion is recommended.Besides treating the frames, it is required to spray the alkus faces immediately before assembling (Fig. 5.2).MEVA suggests the use of a sol vent-based release agent.Make sure not to spray too much of the release agent, since a thick separa ting layer tends to be sticky.The additional use of release agent is determined by jobsite conditions.

Application of a stain-less steel jet The release agent must be sprayed only in thin layers, so that the solvent can evaporate immedi­ately and only a very thin fi lm coating remains. Therefore, it is recommended to use a stainless steel jet, which pro duces a steady fi ne mist (Fig.5.1).

WaxA fl uid wax is re­commended for all types of formwork. It is either sprayed or applied evenly with a brush or a sponge to those parts of the formwork that will not get into contact with concrete. We suggest to spray the panel stacks (wall and slab forms) all around (Fig. 5.3 - Fig. 5.4).As ever, the facing should be sprayed with release agent, since any wax remnants on the concrete might lead to prob lems with fi nis hing works.

Fig. 5.1Fig. 5.2Fig. 5.3Fig. 5.4 Description Ref.-No.

Stainless steel jet ..29-203-94Sprayer .................29-903-70Wax .....................29-203-95

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Repair

Repair of scratchesCoarse damages or single deep scratches are repaired with the same plastic ma te ri al as the upper layer of the alkus-sheet consists of: Poly­propylene. The result is a high-quality sur face ready for the next application (Fig. 6.1).

Repair with patchesSurface damages caused by vibrators or reinforcement are repaired with plastic patches with a dia­meter of 2" (5 cm) (Fig. 6.4).The maximum area of surface damages to be repaired can be the size of a hand. For this, several patches are put in a row.

Repair procedureUse the hot air welder to preheat the thermoplastic ma te ri al at the damaged spot. In case of scratches fi ll the damaged area with the heated polypro pylene welding rod (Fig. 6.1). A commercial paint remover is used to grind off protruding parts (Fig. 6.3).Drill holes and greater damages are drilled thoroughly and fi lled with plastic patches. Drill holes and other holes up to a diameter of 1" (2.5 cm) are repaired with a plastic plug (Fig. 6.2).

In case of greater damage a complete section of an alkus sheet is welded be-tween two cross stiffeners of a wall or slab form panel.

alkus-repair setFor the repair of the alkus-sheets a complete repair set is available. Nevertheless, all tools can be ordered sepa­rately (Fig. 6.5).

Description Ref.-No.

alkus-repair set .....29-912-00

Aluminum box

(without contents) 28-100-10

Hot air welder ......29-912-10

Quick clamping

welding nozzle .....29-912-15

Metabo paint

remover ................29-912-20

Spare knives for Metabo

paint remover .......29-912-22

Drilling machine ...29-912-30

Stand for drilling

machine ...............29-912-35

Special step

drill bit .................29-912-50

Carbide cylinder

head drill bit .........29-912-55

Scraper .................29-912-70

Side cutting pliers .29-912-75

Depth gauge (6mm) 29-912-80

Welding rod,

PP 20 m (65') .......29-912-95

Repair plug 23 ......29-913-10

Repair plug 20 ......29-913-15

Repair plug17 .......29-913-20

Repair patch D 35 29-913-25

Repair patch 2" ....29-913-30

AS­conical tube

D29/24 .................42-010-16

Fig. 6.1 Fig. 6.2Fig. 6.3 Fig. 6.4

Fig. 6.5

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Cleaning and replacement

Professional cleaning If using a profes sional cleaning machine, make sure to use only appro priate plastic brushes.

Replacement of plywoodMEVA offers the new and durable alkus-sheets for mo du lar forms of all common brands.The new plastic sheets have the same life span as the frame.

Hints on replace mentTemperature effects might cause that the aluminum layer of the alkus-sheet shears off the screw heads. Therefore, the drill hole should be 3/64" (1 mm) more in diameter than the diameter of the screw (Fig. 7.4).

Cleaning after strippingIn principle, cleaning should not be carried out with hard and scratching metallic devices, like scrapers with hard metalblades (Fig. 7.1).

Manual cleaningSpatulas, a piece of hardwood or a wet cloth are suffi cient to remove concrete rem­nants from the alkus

Rotation cleanerMake sure to attach only a plastic pad to the rotary disc so that the alkus­sheet will not be damaged. We recommend to use water plus sawdust (Fig. 7.2).

High pressure cleaningThe most effective way to clean the panels is with a high pressure cleaner. The water consumption for this is extremely little. You can also use this steam jet to hose down the formwork after pouring (Fig. 7.3).

Fig. 7.1Fig. 7.2Fig. 7.3

Fig. 7.4 Description Ref.-No.

Cleaning grid d=406 mm (16") ..28-502-35Cleaning pad ........28-502-30

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Recycling

Already during the design stage of the alkus, the hund red percent recyclability was among the in dis pen sab le requirements.The diagram on the right explains how old and used panels are recycled into identical products with the alkus recycling con cept. This means a hundred percent recycling.MEVA guarantees the acceptance of returned alkus-sheets, worldwide.

Fig. 8. 1

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Technical data

Tab. 9.1

Reinforcing Layer Glass Fibers AluminumTest-

Standard

Type of PanelGM 6

GM 10

GM 12

AL 13

AL 15

AL 17

AL 20

AL 21

AL 23

Reference Thickness (mm) 5.7 10.0 11.5 13.0 15.0 17.0 20.0 21.0 23.0

Thickness Tolerance / Deviation (mm) +0/­0.6 +0/­0.6

Density (kg/m³) 1000 900 830 810 765 735 725 715 705

Weight (kg/m²) 5.7 9.0 9.5 10.5 11.5 12.5 14.5 15.0 16.2

Modulus of Elasticity (3­point) longitudinal diagonal

4.4302.140

3.6502.100

3.0001.850

6.500 6.350 5.850 5.100 5.200 4.300 ISO 178

Tensile Strength, 21°C (N/mm²) longitudinal diagonal

9047

7036

6037

53 53 44 42 44 37 ISO 178

Modulus of Elasticityunder working conditions (N/mm²)

­ 3.850 3.800 7.600 8.350 7.400 5.950 6.650 5.200 EN 408

Modulus of Shear (N/mm²) ­ 58 57 110 109 108 143 131 134 EN 408

Shear Resistance (N/mm²) > 6 EN 789

Thermal Properties

Thermal Conductivity (W/(m K)) ­ 0.11

Thermal Expansion Coeffi cient,(10­6 m/(m K))

70 42

Long­Term Heat Resistance > 90°C > 90°C ISO 75

Fire behavior B2 normally infl ammable DIN 4102

Other Properties

Water Absorbation / Change of Dimensions 0% 0%

Nail Holding Ability comparable with plywood sheets coated with phenolic resin

Surface hardness (Shore D) 70 66

Scratch Resistance (N) 0.70 0.50 DIN 53799

Abrasion Resistance (AT 1/rotations) > 28.000 > 11.000 DIN 53799

Processing at site: like woodindustrial production: with optimized cutting and drilling geometries

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MEVA Formwork Systems, Inc.2000 Airpark Drive Springfi eld, OH 45502Phone (937) 328-0022Toll free 1-866-367-6382Fax (937) 328-0044e-mail: mailus@mevaformwork.comInternet: www.mevaformwork.com